JP2010201338A - Method of manufacturing metal plate with coating film having joint edge - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a metal plate with a coating film which can prevent deterioration of design and improve a degree of freedom of the structure and to which joint can be applied. <P>SOLUTION: The method of manufacturing a metal plate with a coating film having a joint edge is provided which comprises a process for forming a release layer of a desired pattern on the metal plate, a process for forming the coating film on the metal plate formed with the release layer, and a process for forming the joint edge for jointing a member to be jointed by exposing the metal plate along the pattern by releasing the coating film together with the release layer. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a method for producing a coated metal sheet. More specifically, the present invention relates to a method for producing a metal plate with a coating film, which is devised to enhance the bonding force with a member to be bonded.

  In pre-painted metal plates (metal plates with a coating film) that are widely used in the fields of automobiles, building materials, household electrical appliances, general goods, etc., since the coating film is an insulator, welding is simply performed. There are drawbacks that the film cannot be formed or the coating film is dissolved by heat. Therefore, in general, as a method of joining the metal plates with a coating film, a method of adhesive joining with an adhesive or the like has been proposed.

  However, since the flat coating surface is simply bonded with an adhesive, the adhesive and the coating peel off or the coating itself from the metal plate when strong stress is applied or the bonded part deteriorates with time. Peeled off and the bonded part was broken.

  As a method for solving such a problem, a method has been disclosed in which a hole is formed in a metal plate with a coating film and an adhesive is sandwiched to extrude the adhesive from the hole to the opposite side to form a rivet-like adhesive surface. (Patent Document 1).

JP 2000-001650 A

  In the said patent document 1, compared with the method of adhering simply with an adhesive agent, joint strength improves.

  However, since it is necessary to make a hole without fail, for example, when a technique is applied to a part that can be touched by human eyes (for example, a door of an automobile), the appearance is deteriorated and the design is deteriorated. In addition, since it is necessary to make a hole, there are structural restrictions. In the first place, if the metal plate with a coating can be simply welded, the bonding force can be sufficiently secured, so there is no need to perform adhesive bonding with an adhesive or mechanical bonding using rivets. There is no such technology in the board yet.

  The present invention has been made in view of the above circumstances, and manufactures a metal plate with a coating film that prevents deterioration in designability, improves the structural freedom, and can apply bonding. It aims to provide a method.

  The present inventors have intensively studied to solve the above problems. As a result, a release layer that facilitates peeling of the coating film is formed on the part to be joined to the member to be joined on the metal plate, and after coating, the coating film is peeled off together with the release layer. The problem is solved by providing a metal plate.

  According to this invention, the coating film in a metal plate with a coating film can be peeled easily, and the part which peeled functions as a joining allowance which can be joined firmly to a to-be-joined member. And since there is no coating film in joining allowance, an adhesive etc. can be directly applied to a metal plate. Moreover, since there is no coating film, welding can be performed simply.

  As such, it is possible to provide a method for producing a drastic metal plate with a coating film that prevents deterioration in designability, improves the structural freedom, and is applicable to bonding.

Drawing 1 is a figure showing roughly the form which manufactures the joined object containing a metal plate with a coating film by joining the metal plate with a coating film which has joining margin to a member to be joined. FIG. 2 is a view including a step of manufacturing a metal plate with a coating film having a bonding margin, and a step of bonding a member to be bonded to the bonding margin of the metal plate with a coating layer. It is a manufacturing flow of the body. FIG. 3 is a cross-sectional view schematically showing a metal plate on which a release layer having a desired pattern is formed. FIG. 4 is a cross-sectional view showing a form in which at least a part of a portion of the metal plate where the release layer is formed protrudes to form a convex portion. FIG. 5 is a cross-sectional view schematically showing a form in which a coating film is formed on a metal plate on which a release layer is formed. FIG. 6 is a cross-sectional view schematically showing a form in which a coating film is formed on a metal plate in which at least a part of a part where a release layer is formed protrudes and a convex part is formed. FIG. 7 is a cross-sectional view schematically showing a coating film in which an electrodeposition layer, an intermediate coating layer, a top coating layer, and a clear layer are laminated in this order on a metal plate on which a release layer is formed. . FIG. 8 is a cross-sectional view schematically showing a form in which a pressure-sensitive adhesive tape is bonded to a metal plate on which a release layer is formed and a coating film is formed. FIG. 9 schematically shows a form in which a pressure-sensitive adhesive tape is bonded to a metal plate in which at least a part of a part where a release layer is formed protrudes and a convex part is formed and a coating film is formed. It is sectional drawing. FIG. 10 is a cross-sectional view schematically showing a form in which the coating film is peeled from the metal plate with a coating film together with the release layer, and a metal plate with a coating film having a bonding margin is manufactured. FIG. 11 is a cross-sectional view schematically showing a form in which a coating film is peeled from a metal plate with a coating film together with a release layer, and a metal plate with a coating film having a bonding margin is manufactured. FIG. 12 is a cross-sectional view schematically showing a form in which an adhesive is applied over the whole on a metal plate with a coating having a bonding allowance. FIG. 13 shows a coating-coated metal plate having a bonding margin in which an adhesive is applied over the entire area, and a coated metal plate having a bonding margin in which an adhesive is applied over the entire area. The form which joins via is shown with sectional drawing. FIG. 14 is a cross-sectional view showing a form in which a metal plate with a coating film having a joining margin to which an adhesive is applied over the whole and a metal plate are joined via an adhesive.

  The first of the present invention is a step of forming a release layer having a desired pattern on a metal plate, a step of forming a coating film on the metal plate on which the release layer is formed, and the release Forming a joining allowance for exposing the metal plate along the pattern and joining a member to be joined by peeling the coating film together with the layer, and having a joining allowance It is a manufacturing method.

  Moreover, the 2nd of this invention is the process of manufacturing the metal plate with a coating film which has a joining margin by the 1st method of this invention, and the process of joining a to-be-joined member to the joining margin of the said metal plate with a coating film. And a method for producing a joined body including a metal plate with a coating film.

  As mentioned above, the problem at the time of joining the metal plate with a coating film has been pointed out conventionally, and there exists a technique like patent document 1 in order to solve the problem. In addition, for example, development of an adhesive having good adhesion to a coating film has been performed. However, when the coating film is formed of a plurality of layers, the lower strength layer may peel off from the base point or cause cohesive failure, and there is a problem that the bonding strength is not sufficient. It was.

  The present inventors have conducted intensive research to solve such problems. In the process, we focused on the original cause of this problem (that is, the coating film itself).

  In other words, because it is due to the presence of the coating film on the metal plate with a coating film, the above problem is caused by making it a form that is not a metal plate with a coating film only at the joining portion while taking advantage of the metal plate with a coating film. It was examined whether it could not be solved.

  The premise is that the coated metal plate has a coated film. However, the natural premise was defeated, and the part of the metal plate with the coating film that would be joined to the member to be joined on the metal plate was predicted, and that part of the coating film was peeled off and firmly joined to the member to be joined. It has been found that the above problem can be solved by exposing a metal plate that can be removed.

  That is, a release layer that facilitates peeling of the coating film is formed on the metal plate, and the coating plate is peeled off together with the release layer, thereby exposing the metal plate and providing a joining margin for joining the members to be joined. As a result of the formation, the inventors have found that the above-mentioned problem is drastically solved, and the present invention has been completed.

  Hereinafter, the present invention will be described in detail with appropriate reference to the drawings. In addition, since the following embodiment is only one specific example of this invention, it cannot be overemphasized that this invention is not limited to this specific example. Each drawing is exaggerated for convenience of explanation, and the dimensional ratio of each component in each drawing may be different from the actual one.

  FIG. 1 is a view schematically showing a form in which a bonded body C including a metal plate with a coating film is manufactured by bonding a metal plate A with a coating film having a bonding margin to a member B to be bonded.

  The metal plate A with a coating film having a bonding margin includes a metal plate 11, a coating film 12 formed on the metal plate 11, and a bonding margin 13 for bonding a member to be bonded from which the metal plate 11 is exposed. It consists of.

  The to-be-joined member B is the metal plate 11, the coating film 12 formed on the said metal plate 11, and the to-be-joined member which the metal plate 11 exposed like the metal plate A with a coating film which has joining allowance. It is comprised from the joining allowance 13 for joining. When the member B to be joined is thus in the same form as the metal plate A with a coating having a bonding allowance, it is preferable in terms of improving the adhesion between the two metal plates with a coating. .

  The joined body C including the metal plate with a coating film can be manufactured by bonding the metal plate A with a coating film having a bonding allowance and the member B to be bonded using the adhesive 14. In addition, since the adhesive 14 has viscosity, the joined body C including the metal plate with a coating film is manufactured in a form in which the joining margin 13 is buried.

  Then, in FIG. 2, the metal plate with a coating film including the process of manufacturing the metal plate with a coating film which has a joining margin, and the process of joining a to-be-joined member to the joining margin of the said metal plate with a coating film. A manufacturing flow of a joined body including the above will be schematically described. Needless to say, the present invention is not limited to the following forms.

(1) Mold release layer formation In this embodiment, the mold release layer 21 of a desired pattern is formed on the blank material (metal plate 11) of the door of the car cut out for shaping | molding. FIG. 3 is a cross-sectional view schematically showing a metal plate on which a release layer having a desired pattern is formed.

  Although there is no restriction | limiting in particular as the metal plate 11, For example, when using for a motor vehicle, it is preferable that it is a steel plate. The thickness of the metal plate 11 is not particularly limited, but is preferably about 0.6 to 1.6 mm.

  The release layer 21 is provided to form a joining margin for joining the members to be joined. That is, by forming the release layer 21, the coating film can be peeled together with the release layer 21. By doing so, the metal plate 11 can be exposed, and the portion where the metal plate 11 is exposed serves as a joining margin for joining the members to be joined. In consideration of workability, it is preferable to form a release layer before molding.

  Here, the desired pattern of the release layer 21 can be appropriately set depending on the position where the bonding margin is provided. However, before molding, and where the release layer is formed, the elongation and friction with the press die change at the time of molding, so how should the part to be joined (ie, joining margin) be located? The question is whether to predict. This problem can be solved by performing a molding simulation in advance or performing a trial molding (trial hitting). According to the forming simulation, it is possible to derive which part is squeezed how much and which part deforms into which part in the metal plate having a desired pattern. Further, if trial molding is performed, it is possible to actually confirm the friction and elongation of the part where the release layer is formed during molding.

  The release layer 21 is not particularly limited as long as it can easily peel the coating film from the metal plate with a coating film. For example, an oxide film can be formed on the metal plate by irradiating the metal plate with a laser, or applying a chemical and heating, and the oxide film can be used as a release layer. When the release layer is an oxide film, it is preferable because the coating film can be peeled off surprisingly easily and cleanly. This effect is particularly remarkable when the metal plate is a steel plate. Moreover, you may use a mold release agent, a masking agent, a masking tape, etc. as a mold release layer.

  The width and thickness of the release layer 21 are not particularly limited as long as the coating layer can be easily peeled together with the release layer and can sufficiently function as a bonding allowance. Since the width of the release layer becomes the width of the joining allowance, it is preferable to take the joining allowance into consideration when determining the width of the release layer.

  The width that can sufficiently function as a joining allowance varies depending on the joining method (for example, the type of adhesive) and the area (volume) of the release layer to be formed, but how much force is applied to the joining allowance. Can be determined by assuming That is, the width of the release layer (the width of the joining allowance) can be determined based on the balance between the joining force of the coated metal plate and the member to be joined and the assumed force (required force). For example, assuming a general automobile door, when the thickness of the metal plate is about 0.6 to 1.6 mm, the width of the release layer is preferably about 10 mm and the thickness is about 2 μm. . Of course, those skilled in the art can make appropriate changes.

(2) Molding Subsequently, the metal plate on which the release layer is formed is molded. Forming before forming the coating film is preferable in that it is possible to prevent cracking of the coating film accompanying the forming. Of course, after the coating film is formed, the metal plate on which the coating film is formed may be molded. In that case, a special coating material that does not crack even when bent may be used.

  The molding method can be performed by appropriately referring to or combining conventionally known knowledge, but it is preferable to perform press molding as shown in FIG. When performing the press molding, a conventionally known process (for example, cutting unnecessary portions (cutting process), bending a corner (bending process)) may be appropriately performed as necessary.

  Moreover, when shaping | molding supposing an actual joining body, you may give a device which makes it easy to peel a mold release layer to a metal plate. FIG. 4 is a cross-sectional view showing a form in which at least a part of a portion of the metal plate 11 where the release layer 21 is formed protrudes and a convex portion is formed. Forming such a convex portion is preferable in that the portion becomes a base point (trigger) and the release layer is easily peeled off.

(3) Molded product Subsequently, a molded product is manufactured by molding a metal plate on which the release layer is formed.

(4) Coating Subsequently, a coating film is formed on the metal plate (molded product) on which the release layer is formed.

  In this embodiment, it can be said that it is very advantageous as compared with the prior art in that coating can be performed before joining (assembly). That is, conventionally, particularly in the field of automobiles, it has been difficult to apply coating to a molded product before assembling because of the problem of bonding strength that occurs when the coated metal plates are bonded together. On the other hand, since the assembled assembly generally has a complicated shape such as a bag structure, there is a problem that uneven coating occurs when coating is performed.

  In the present embodiment, since a metal plate with a coating previously coated with a metal plate is used, coating unevenness can be prevented in the first place, and a bonded body excellent in design can be provided. And since the metal plate with a coating film of this embodiment has the joining margin which can be joined firmly to a member to be joined (adhesive etc. can be directly applied to a metal plate, and welding is simple. Therefore, it can be said that it is an epoch-making thing which solved also the problem of the said joint strength.

  In the present embodiment, the coating method is not particularly limited, and appropriate coating can be performed by appropriately referring to or combining conventionally known knowledge.

  FIG. 5 is a cross-sectional view schematically showing a form in which the coating film 12 is formed on the metal plate 11 on which the release layer 21 is formed. FIG. 6 is a modification of the embodiment of FIG. 5, and the coating film 12 is formed on the metal plate 11 where at least a part of the portion where the release layer 21 is formed protrudes and a convex portion is formed. FIG.

  The coating film 12 may be formed by laminating a plurality of layers from the viewpoint of improving the adhesiveness and design properties with the metal plate 11. FIG. 7 shows a form in which a plurality of coating films are laminated. On the metal plate 11 on which the release layer 21 is formed, an electrodeposition layer 12a, an intermediate coating layer 12b, a top coating layer 12c, It is sectional drawing which represents typically the coating film 12 by which the clear layer 12d is laminated | stacked in this order. If necessary, a configuration in which a pearl layer is provided between the overcoat layer 12c and the clear layer 12d may be used (not shown).

  When the adhesive is applied to the coating film and the metal plates with the coating film are joined to each other as in the past, particularly when the coating film is formed of a plurality of layers as shown in FIG. The layer (between the intermediate coating layer 12b and the top coating layer 12c according to the experiments by the inventors) may peel off or cause cohesive failure. If there is a problem between the intermediate coating layer 12b and the top coating layer 12c, there is an idea that the intermediate coating layer 12b is not formed. However, there may be a problem that the designability is deteriorated, or a problem of bonding strength between the clear layer 12d and the intermediate coating layer 12b. Moreover, since the coating film 12 is an insulator, there are drawbacks that welding cannot be performed simply or the coating film is melted by heat.

  According to this embodiment, since the metal plate 11 having a significantly strong adhesive force can be exposed by peeling the coating film 12 together with the release layer 21, the bonding strength can be increased when the members to be bonded are bonded. A joined body including a coated metal plate can be produced without any problem. Moreover, according to this embodiment, since the metal plate 11 is exposed (because the coating film 12 is peeled off), welding can be easily applied with the exposed metal plate 11 (joining allowance).

(5) Peeling Subsequently, by peeling the coating film 12 together with the release layer 21 from the metal plate with a coating film, the metal plate 11 is exposed along the pattern of the release layer 21, and the members to be joined are joined. The joint allowance is formed. In order to peel the coating film 12 together with the release layer 21 from the metal plate with a coating film, for example, an adhesive tape is bonded so as to cover the entire coating film 12 formed on the release layer 21, and then the adhesive tape Can be raised. In the present embodiment, the release layer 21 exists at the lower part of the coating film 12, but the part between the release layer 21 and the metal plate 11 is the portion with the weakest bonding force. The coating film 12 can be peeled from the metal plate with a coating film.

  FIG. 8 is a cross-sectional view schematically showing a form in which the adhesive tape 31 is bonded to the metal plate 11 on which the release layer 21 is formed and the coating film 12 is formed. FIG. 9 is a modification of the embodiment of FIG. 8, in which at least a part of the metal plate 11 where the release layer 21 is formed protrudes and a coating 12 is formed on a protrusion. It is sectional drawing which represented typically the form by which the adhesive tape 31 was adhere | attached. In the modification shown in FIG. 9, since the part which pulls up the adhesive tape 31 is a convex part shape previously, it is preferable at the point which can pull up an adhesive tape very easily.

  In FIG. 8, when the adhesive tape 31 is pulled up, as shown in FIG. 10, the coating film 12 is peeled off from the metal plate with a coating film together with the release layer 21, and the coated metal plate A having the joining allowance 13 is easily obtained. Can be manufactured. 9, when the pressure-sensitive adhesive tape 31 is pulled up, as shown in FIG. 11, the coating film 12 is peeled off from the coating-coated metal plate together with the release layer 21, and the coating-coated metal plate A having the joining allowance 13 is obtained. It can be manufactured easily.

  When the release layer 21 is an oxide film, as shown in FIGS. 10 and 11, a trace (oxide film trace 21 a) in which the release layer (oxide film) 21 is formed remains on the metal plate 11. . In this case, the bonding margin 13 including the oxide film trace 21a is referred to. When the release layer 21 is a release agent or a masking agent, no trace such as the oxide film trace 21a remains. However, since there is a possibility that the release agent and the masking agent may remain on the metal plate, it is preferable to wipe them off in order to strengthen the bonding force later when bonding to the member to be bonded. . When the release layer 21 is an oxide film, there is no need for a wiping operation or the like, and it is also preferable in that the bonding force is strong.

  As described above, by peeling the coating film 12 together with the release layer 21 from the metal plate with a coating film, the metal plate 11 is exposed along the pattern of the release layer 21, and bonding for bonding the members to be bonded. Thirteen can be formed. In the bonding allowance 13, since the coating film 12 does not exist, an adhesive or the like can be directly applied to the metal plate 11. Moreover, since the coating film 12 does not exist, welding can be performed simply. As such, it is possible to provide a method for producing a drastic metal plate with a coating film that prevents deterioration in designability, improves the structural freedom, and is applicable to bonding.

(6) Joining Finally, the coated metal plate having the joining allowance manufactured in (1) to (5) is joined to the member to be joined, and a joined body including the coated metal plate is produced.

  As described above, in the present embodiment, while utilizing the advantages of the metal plate with a coating film (because coating can be performed before assembly, coating unevenness does not occur and the design is excellent) In “,” the form is not a metal plate with a coating film to strengthen the bonding force. In this way, the problem in the present embodiment can be solved.

  FIG. 12 is a cross-sectional view schematically showing a form in which the adhesive 14 is applied over the entire surface of the coated metal plate A having the bonding allowance 13. By applying the adhesive 14 over the entire coated metal plate A having the bonding allowance 13, unnecessary gaps are eliminated and rusting of the metal plate 11 is prevented. In addition, since there is a site | part by which the adhesive agent 14 is directly apply | coated on the coating film 12, since it is thought that the intensity | strength of this site | part becomes a problem, since the intensity | strength of joining is decided by the part of the joining margin 13, it is a problem. Don't be.

  The adhesive 14 can be used with reference to known knowledge or in combination, but preferably has a strong bonding force to the metal plate 11.

  FIG. 13 shows a metal plate A with a coating film having a joining allowance 13 to which the adhesive 14 is applied over the whole, and a metal plate B with a coating film having a joining allowance 13 to which the adhesive 14 is applied over the whole. Are shown in a cross-sectional view through a bonding agent 14 (note that the coated metal plate B having the bonding allowance 13 corresponds to the “joined member” in the present specification). . In this embodiment, an adhesive is applied to both, which is preferable from the viewpoint of bonding strength. Moreover, when joining the metal plates with a coating film, it is preferable at the point that a strong joining force can be ensured. Of course, as shown in FIG. 1, the adhesive may be applied to only one of the two, and the two may be joined via the adhesive. This form is suitable when workability is taken into consideration. Furthermore, as shown in FIG. 14, the member B to be joined may have only the metal plate 11 without having a coating film. In this form, it is preferable at the point which joins the metal plate with a coating film which has the joining allowance 13 with the to-be-joined member which does not need to apply | coat.

  Although not shown, it is possible to join the member to be joined by welding using a joining margin. The welding method is not particularly limited and can be applied with reference to known knowledge or in combination. Spot welding is preferable in the field of automobiles and sheet metal.

As described above, the peeled portion functions as a bonding allowance that can be firmly bonded to the member to be bonded. And since there is no coating film in joining allowance, an adhesive etc. can be directly applied to a metal plate. Moreover, since there is no coating film, welding can be performed simply.
As such, the design is prevented from being deteriorated, the degree of structural freedom is improved, and the metal plate with a coating film to which bonding can be applied and the joint material are bonded to produce a bonded body. A method can be provided.

  In addition, when manufacturing a joined body including a metal plate with a coating film by joining the metal plate with a coating film having a bonding allowance of the present embodiment to a member to be joined, Mechanical joining using rivets or bolts may be performed. This mechanical joining is preferable in that the joining can be further strengthened. However, the particularly excellent point in the present embodiment is that the metal plates with a coating film are bonded to each other using an adhesive even if the design property is required or the structure is not free. The point that is the point that can be welded is added at the end.

A metal plate A with a coating having a bonding allowance,
B member to be joined,
C joined body C including a metal plate with a coating film,
11 Metal plate,
12 coating film,
13 Joining fee,
14 Adhesive,
21 release layer,
21a oxide film trace,
31 Adhesive tape.

Claims (7)

Forming a release layer having a desired pattern on a metal plate;
Forming a coating film on the metal plate formed with the release layer;
Peeling the coating film together with the release layer to expose the metal plate along the pattern to form a joining margin for joining the members to be joined;
The manufacturing method of the metal plate with a coating film which has a joining allowance.   The manufacturing method according to claim 1, wherein the release layer is formed from an oxide film or a release agent formed by oxidizing the metal plate.   The manufacturing method of Claim 1 or 2 which further includes the shaping | molding process of shape | molding the said metal plate in which the said release layer is formed before forming the said coating film.   The manufacturing method according to claim 1, further comprising a forming step of forming the metal plate on which the coating film is formed after forming the coating film.   The manufacturing method according to claim 3 or 4, wherein, in the step of forming the metal plate, at least a part of a portion of the metal plate where the release layer is formed is protruded to form a convex portion. The process of manufacturing the metal plate with a coating film which has a joining margin by the method of any one of Claims 1-5,
In the joining margin of the metal plate with a coating film, a step of joining a member to be joined,
The manufacturing method of the conjugate | zygote containing the metal plate with a coating film containing.   The manufacturing method of Claim 6 which joins the said metal plate and the said to-be-joined member by an adhesive agent or welding.

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